Packing film with a top layer forming a predefined opening track

Abstract

The invention is directed to a packaging film (2) comprising: a top layer (4) with at least one aperture (4.1); a bottom layer (8) adhered to the top layer (4); a tear layer (6) adhered to the bottom layer (8) and extending along the at least one aperture (4.1) so that upon traction on the tear layer, said layer tears the bottom layer (8) through the aperture(s) (4.1). The tear layer (6) extends beyond the at least one aperture (4.1), between the top layer (4) and the bottom layer (8), preferably longitudinally in two opposite directions. The invention also relates to a condom wrapping with such a film and to the manufacturing method for such a film.

Claims

1. Packaging film comprising: a top layer with at least one aperture; a bottom layer adhered to the top layer; a tear layer adhered to the bottom layer and extending along the at least one aperture so that upon traction on the tear layer said layer tears the bottom layer through the at least one aperture; wherein the tear layer extends beyond the at least one aperture, between the top layer and the bottom layer longitudinally in two opposite directions; and wherein the tear layer comprises a pull tab which is unitary with the tear layer and formed by a portion of said tear layer that is folded on itself.

2. The packaging film according to claim 1, wherein the tear layer is weakened along a portion of the contour of the at least one aperture so as to break and separate when exerting traction on the tear layer.

3. The packaging film according to claim 1, wherein the portion of tear layer folded on itself and forming the pull tab is embossed so as to form a gripping relief structure.

4. The packaging film according to claim 1, wherein the pull tab forms a hinge with a portion of the tear layer that is adhered to the lower layer in the at least one aperture, said hinge being formed by two adjacent folds of the tear layer portion folded on itself, with said adhered portion.

5. The packaging film according to claim 4, wherein the portion of tear layer that is adhered to the lower layer in the at least one aperture is formed by two sub-portions which are juxtaposed by folding the portion forming the pull tab.

6. The packaging film according to claim 4, wherein the pull tab is linked to the portion of tear layer that is adhered to the lower layer in the at least one aperture at a position of said portion that is distant from the contour of said aperture, said distance being within the range of from ⅙ to ¼ of the width of said aperture along a pulling direction of said pull tab.

7. The packaging film according to claim 4, wherein the portion of tear layer that is adhered to the lower layer in the at least one aperture overlaps with the top layer by a distance d that within the range of from 0.1 mm to 5 mm.

8. The packaging film according to claim 1, wherein the pull tab extends through the aperture.

9. The packaging film according to claim 1, wherein the apertures and pull tabs are distributed longitudinally evenly, the tear layer forming a continuous strip along said apertures, the packaging film being rolled on a mandrel.

10. The packaging film according to claim 1, wherein the film comprises a pull tab which is adhered to the tear layer, the pull tab being a portion of the top layer corresponding to the aperture.

11. The packaging film according to claim 1, wherein the film comprises a pull tab which is adhered to the tear layer, the pull tab being adhered to the tear layer only over a portion of said pull tab so as to leave another portion for grasping.

12. The packaging film according to claim 1, wherein the film comprises a pull tab which is adhered to the tear layer, the tear layer being weakened along a contour that corresponds to the at least one aperture.

13. The packaging film according to claim 1, wherein the tear layer has an external contour that corresponds to the at least one aperture.

14. The packaging film according to claim 1, wherein the tear layer is a strip of tear resistant material.

15. The packaging film according to claim 1, wherein the at least one aperture is circular or oval.

16. The packaging film according to claim 1, wherein the top layer is thicker and/or more resistant than the bottom layer.

17. The packaging film according to claim 1, wherein the bottom layer is a laminate with an impermeable plastic sheet and/or an aluminum sheet.

18. A condom wrapping comprising two superimposed sections of packaging film joined at the edges to form a container housing a condom in a rolled-up state with a condom vessel in a normal position adjacent to one of the two sections of film, the normal direction of unrolling the condom being towards the other section of film, wherein the section of film adjacent to the vessel is a film comprising: a top layer with at least one aperture; a bottom layer adhered to the top layer; a tear layer adhered to the bottom layer and extending along the at least one aperture so that upon traction on the tear layer said layer tears the bottom layer through the at least one aperture; wherein the tear layer extends beyond the at least one aperture, between the top layer and the bottom layer longitudinally in two opposite directions.

19. A method for manufacturing a packaging film comprising: a top layer with apertures; a bottom layer adhered to the top layer; a tear layer adhered to the bottom layer and extending along the apertures so that upon traction on the tear layer said layer tears the bottom layer through the apertures; wherein the tear layer extends beyond the apertures, between the top layer and the bottom layer longitudinally in two opposite directions; wherein the tear layer comprises pull tabs which are unitary with the tear layer and formed by a portion of said tear layer that is folded on itself; the method comprising the following steps: (a) forming the pull tabs unitary with a strip of the tear layer by folding on itself and adhering portions of said strip at regular intervals; (b) inserting the strip of tear layer with the pull tabs between the top layer and the lower layer by bringing into register the pull tabs and the apertures, and adhering portions of said strip to said lower layer.

20. The method according to claim 19, wherein step (a) comprises: embossing a gripping relief structure on the strip portions forming the pull tabs, and step (b) comprises: bringing the pull tabs into the corresponding apertures of the top layer by applying a gas stream in front of said apertures.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows an exploded view of the packaging film according to a first embodiment of the invention;

(2) FIG. 2 shows two perpendicular cross sectional views of the packaging film according to the first embodiment of the invention;

(3) FIGS. 3 to 5 show a top view of a package with a packaging film according to a second embodiment of the invention and the respective tear layer;

(4) FIGS. 6 to 8 show a top view of another package with a packaging film according to a third embodiment of the invention and the respective tear layer;

(5) FIG. 9 shows various additional exemplary embodiments of packages with a packaging film according to the invention;

(6) FIGS. 10 to 12 depict the successive steps of manufacture of a packaging film according to the invention;

(7) FIG. 13 is a top view of a package with a packaging film according to a fourth embodiment of the invention;

(8) FIG. 14 is a cross-sectional view of the top packaging film of the package of FIG. 15;

(9) FIG. 15 is an exploded view of the top packaging film of FIGS. 13 and 14.

DESCRIPTION OF AN EMBODIMENT

(10) FIGS. 1 and 2 illustrate a first embodiment of packaging film of the invention.

(11) FIG. 1 shows an exploded view of the components of the packaging film according to a first embodiment. The packaging film 2 is made of multiple layers. The packaging film 2 comprises a top layer 4 with apertures 4.1. The top layer 4 is continuous and preferably untearable. It can be die cut mechanically or by laser techniques.

(12) Directly below the top layer 4, a tear layer 6 is provided. It consists in this example of a strip comprising a series of pull tabs 6.1 and elongated portions 6.2 that are adhered to a bottom layer 8. Each pull tab 6.1 forms a hinge 6.3 with the portion 6.2. Each portion 6.2 is also weakened transversely 6.4 so as to allow a separation of the strip wen exerting a traction on the corresponding pull tab 6.1. Each pull tab 6.1 can be formed by folding on itself a portion of the strip, the free end 6.5 of said pull tab 6.1 corresponding to the fold of said portion.

(13) The bottom layer 8 can be made of a continuous material. The bottom layer 8 can be made of a plastic layer 8.1 and a metal layer 8.2, such as Aluminium. The strip 6 has preferably one or more of the following properties: continuous, untearable, low elasticity, adhesive, foldable, ability to be carved, maybe covered by Aluminium and/or weldable.

(14) FIG. 2 depicts two perpendicular cross sectional views of the packaging film of FIG. 1 when the components are assembled. The strip 6 is folded on itself to form the pull tab 6.1, and the hinge 6.3. The portions 6.2 of the strip 6 that is not the pull tab 6.1 adhere to the bottom layer 8. The pull tab 6.1 extends through the aperture 4.1 and is therefore reachable by the user. The weakening 6.4 of the strip 6 is essentially at the level of the contour of the opening 4.1 in the first layer, on the opposite side to the direction of traction on the pull tab 6.1 in order to allow a separation of the strip upon traction on said pull tab. The weakening 6.4 can be made by various methods, including perforating, partially cutting and/or laser etching. The direction of traction on the pull tab is illustrated by a first arrow in the left view of FIG. 2, oriented essentially in the plane of said pull tab 6.1 (as illustrated in FIG. 2) and oriented towards the free end 6.5 of said pull tab. A second arrow in the left view of FIG. 2 illustrates the counter effort to be applied to the film 2, counterbalancing the traction on the pull tab 6.1.

(15) Still with reference with FIG. 2, in particular the right view of FIG. 2, the portion 6.2 of the strip 6 that is adhered to the bottom layer 8 and located in the aperture 4.1 can show a slight overlap d with the top layer 4. This overlap is interesting in that it hides below the top layer 4 the edge of the bottom layer 8 that will be torn by traction on the pull tab 6.1. The tearing of the bottom layer 8 can indeed show some irregularities, depending on the material of said layer. Hiding this edge below the top layer 4 can therefore be useful. In addition, it allows avoid also the appearance, along the contour of the aperture 4.1, of portions of the top surface of the bottom layer when the strip 6 is not perfectly positioned in register with the aperture, due to inherent manufacturing tolerances. The overlap d can be comprised between 0.1 and 5 mm, preferably between 0.2 and 2 mm.

(16) The packaging film 2 of FIGS. 1 and 2 can be used for various packaging applications such as pouches and condom wrapping. The condom wrapping can be made of two superimposed sections of packaging film joined at the edges to form a container housing a condom in a rolled-up state. The section of film that is adjacent to the vessel of the condom, i.e. opposed to the normal direction of unrolling the condom, is then made of the film of FIGS. 1 and 2. The contour of the opening 4.1 in the first layer 4 corresponds then approximately to the contour of the condom, so that upon traction on the pull tab 6.1, the second layer 8 is pulled and torn through the aperture 4.1 and opens the wrapping, providing access to the condom.

(17) FIGS. 3 to 5 illustrate a second embodiment of packaging film and condom wrapping of the invention. Reference numbers of the first embodiments are used in the second embodiment for designating the same or corresponding elements, these numbers being however incremented by 100. Reference is made to the description of these elements in the first embodiment. Specific numbers comprised between 100 and 200 are used for specific elements.

(18) FIG. 3 is a top view of a condom wrapping 100, similar to the above condom wrapping of the first embodiment where however the section of film 102 that is adjacent to the vessel of the condom, i.e. opposed to the normal direction of unrolling the condom, is made with a tear layer strip 106 that is different from the one of the first embodiment. The top layer 104 and bottom layer can remain essentially identical.

(19) The possible overlap of the strip 106 with the top layer 104, already described in relation with FIG. 2, is also visible in FIG. 3, illustrated by the slight distance d between the contour of the aperture 104.1 and the contour of the corresponding portion 106.2 of the strip.

(20) FIGS. 4 and 5 show the strip before it is folded and its position with respect to the aperture 104.1 of the first layer. The strip is made of several parts that are repeated in cycle along the strip. Two rectangular parts, or adjacent strip portions of the same length, are provided to build up the pull tab 106.1 when folded onto each other. When the ends of these two rectangular parts are folded, they form the hinge 106.3 between the pull tab 106.1 and the rest of the strip 106.2. At both opposite ends of the pull tab 106.1 are provided two partial-disc-shaped portions 106.2. These portions 106.2 aim at building a complete disc, when the pull tab is folded. The disc is preferably slightly larger than the aperture 104.1. The two disc-shaped portions 106.2 are finally connected to each other by the folded pull tab 106.1. The pull tab 106.1 makes it possible to manufacture the packaging that has several neighbouring apertures with a single strip. As a way of example, the pitch of the cycle can be approximately 114 mm, the pull tab being 2 times 27 mm, the length of the disc-shaped portion being respectively 9 and 25 mm. The width of the strip can be around 17 mm. The size of the wrapping can be approximately 60 mm×60 mm. Those are mainly examples and the skilled person would obviously adapt the size of the package to the size of its content. Some condoms are indeed stored in rectangular packages. Their shape in the package is therefore oval. The packaging film of the invention can obviously be adapted to such shape, and many others.

(21) FIGS. 6 to 8 illustrate a third embodiment of packaging film and condom wrapping of the invention. Reference numbers of the second embodiments are used in the third embodiment for designating the same or corresponding elements, these numbers being however incremented by 100. Reference is made to the description of these elements in the first and second embodiments.

(22) This embodiment differs from the second embodiment of FIGS. 3 to 5 in that the portions 206.2 of the strip 206 that correspond to the apertures 204.1 is now readily cut in the strip before forming the pull tabs 206.1 by folding. Also, as visible in FIG. 6, the pull tab 206.1 does not overlap on the top layer 204. This is essentially due to a shifting of the hinge 206.3 of the pull tab 206.1 towards the contour of the aperture 204.1. In this particular example, the pull tab 206.1 has still the same dimensions (17 mm×27 mm).

(23) The possible overlap of the strip 206 with the top layer 208, already described in relation with FIGS. 2 and 3, is also visible in FIG. 6, illustrated by the slight distance d between the contour of the aperture 204.1 and the contour of the corresponding portion 206.2 of the strip.

(24) The examples given in FIGS. 3 to 8 are obviously merely illustrative of the invention and do not limit the scope of protection, be it in terms of dimensions, shapes, or form.

(25) FIG. 9 illustrates possible variants of the shaped of the pull tab and of the portion of the strip located in the aperture of the top layer. The choice of the form can result from commercial choice, or have recreational, educative, legal, political or religious purposes.

(26) With reference to the possible overlap of the strip with the top layer, already described in relation with FIGS. 2, 3 and 6, the overlap d as illustrated in the variants of FIG. 9, can vary along the contour of the aperture in the top layer, in particular when the contour of the tear layer in the aperture has a different shape than the contour of the aperture. The overlap d can vary between 0 mm and 5 mm, preferably between 0 mm and 2 mm.

(27) Other various compositions are possible, but in essence, the principle is to assemble several layers having different properties in terms of mechanical resistance.

(28) One or more of the above-mentioned layers can be printed, for instance for commercial or legal reasons, or be provided with labels.

(29) It is to be noted, that although the examples given to illustrate the invention depict a pull tab, any other pulling means can be foreseen. For instance, a string, a clip, a pin or a tongue can be attached to the tear layer. The connection must in such a case be stronger than the resistance of the bottom layer and the tear layer, such that when the user pulls the string/clip/pin/tongue, the package will open and the attachment between the string/clip/pin/tongue with the tear layer will remain.

(30) FIGS. 10 to 12 illustrate the successive steps of a preferred embodiment of a method to manufacture a packaging film according to the invention.

(31) FIG. 10 shows the first step. It consists in the unwinding of the tear layer 6 (106, 206) from a coil or roll 14. The layer can be laminated or only unrolled between rollers 16. It is then forwarded to a mobile clamp 18 consisting of a base and a holder. The axes 6.3 (106.3, 206.3), 6.5 (106.5, 206.5) and 6.3 (106.3, 206.3) illustrate the positions of the strip where it will be folded to form the pull tab 6.1 (106.1, 206.1) and the hinge 6.3 (106.3, 206.3). Prior to the folding process, the strip 6 (106, 206) will be clamped on the other side of the folding axes by a fixed clamp 20. Contrary to the mobile clamp 18, the fixed clamp 20 does not move in the direction of unwinding.

(32) As can be seen in FIG. 11, a second mobile clamp 22 lifts up the strip at the point of folding, i.e. axis 6.5 (106.5, 206.5). While the strip is lifted up, the mobile clamps 18 and 22 move towards the fixed clamp 20 and axes 6.3 (106.3, 206.3) which correspond to the folding points on the strip move as well. The clamp 22 moves up until the folding is complete, i.e. when all three axes coincide.

(33) This situation is depicted in FIG. 12. Once this position is reached, a press 24 will weld or at least adhere the folded portion of the strip to form the pull tab 6.1 (106.1, 206.1). The press 24 can also emboss the strip so as to form a relief on the pull tab. A deformation by suction of one of the side only of the pull tab is also possible.

(34) During the step of pressing and/or embossing, the unwinding process can be stopped. Once the pressing/embossing is completed, the strip can again start its unwinding process.

(35) After the pressing/embossing process, the tear layer strip 6 (106, 206) is assembled with the other layers 4 (104, 204) and 8 (108, 208). This can be done by a laminating process between two rollers.

(36) When the pull tab 6.1 (106.1, 206.1) is longer than the aperture 4.1 (104.1, 204.1) and overlaps on the top layer 4 (104, 204), as in the example of FIGS. 3 to 5, it can be convenient to arrange a suction step to ensure that the pull tab is effectively over the top layer. To this effect, a vacuum pump 26 can be provided at the assembling station.

(37) Glue can be applied on the tear layer strip 6 (106, 206) prior to penetrating into the clamps 18, 20, 22. In such a case, the bases of clamps 18 and 20 can be provided with a glue repellent surface. Alternatively, glue may be added after the folding process, prior to the final lamination process.

(38) FIGS. 13 to 15 illustrate a fourth embodiment of a packaging film and a condom wrapping of the invention. Reference numbers of the second embodiments are used in the fourth embodiment for designating the same or corresponding elements, these numbers being however incremented by 200. Reference is made to the description of these elements in the first and second embodiments.

(39) This embodiment differs from the second embodiment of FIGS. 3 to 5 and from the third embodiment of FIGS. 6 to 8, essentially in that the pull tab is not formed by the tear layer anymore but well be a separate element adhered to the tear layer.

(40) More specifically, the tear layer 306 undergoes no folding anymore as in the previous embodiments and the pull tab is formed by a layer portion 304.2 that is adhered, e.g. with glue 307, to a portion of the tear layer 306.1 in the aperture 304.1 formed in the top layer 304. Advantageously, the pull tab is formed by a portion 304.2 of the top layer 304 that corresponds to the aperture 304.1, i.e. resulting from cutting-out said aperture.

(41) The tear layer 306 is weakened or cut along the contour 306.2 which corresponds at least partially to the contour of the aperture 304.1. The weakening or cutting operation is advantageously done before adhesion of the layers 304, 306 and 308.

(42) The pull tab 304.2 comprises a first portion adhered (307) to the portion 306.1 of the tear layer 306 that is in the aperture 304.1 and a second portion for being grasped by the fingers of a user. The first portion is advantageously smaller than the second one. That portion is also advantageously adjacent the contour of the aperture 304.1 and opposed to the second portion with regard to the pull direction.